Ventilation air distribution box

ABSTRACT

An air distribution box for a ventilation air system comprising a housing defining an air passageway between an inlet and a downstream outlet in communication with the ventilation air system. The outlet is defined in an outlet side wall that is positioned at an acute angle with respect to the plane of the inlet such that at least a portion of the outlet faces a portion of the inlet.

FIELD OF THE INVENTION

This invention relates generally to air distribution boxes for use in aforced air ventilation system and, more particularly, to a return airdistribution box mountable to the structural elements of the structurefor used in such a forced air ventilation system.

BACKGROUND OF THE INVENTION

Convention forced air ventilation systems used in heating and airconditioning system provides central heating or cooling equipment thatis connected to a duct system for movement of air within the structure.Typically, the duct system is a branching network of round orrectangular tubes, which are generally constructed of sheet metal,fiberglass board, or a flexible plastic-and-wire composite, that arelocated within the walls, floors, and ceilings. Preferably, the airventilation system consists of supply ducts and return ducts. Thecentral heating or cooling equipment (such as, for example, furnace, airconditioner, or heat pump) contains a fan that forces heated or cooledair into supply ducts leading to the rooms. The fan gets its air supplythrough return ducts.

Typical duct systems lose 10 to 25 percent of the heating or coolingenergy put out by the central furnace, heat pump, or air conditioner.Homes with ducts in a protected area such as a basement may losesomewhat less than this, while some other types of systems (such asattic ducts in hot, humid climates) often lose more. Maintaining theintegrity of the ducts, in maintenance of the desired interiorcross-sectional area of the ducts due to structural compression and/ordebris build up, and in minimizing leakage through small cracks andseams in the ducting components can provide a very important energyimprovement measure for a structure.

In a conventional air ventilation system, air moves from high pressureto low pressure. To get air to move from the supply duct into the roomit serves, the air in the duct has to be at a higher pressure than theair in the room. Similarly, to move air from the room into the returnduct, the air in that duct has to be at a lower pressure than the air inthe room. The registers are the openings through which this air isintended to move. The fan of the central furnace creates these pressuredifferences. When the fan stops, these pressures quickly equalize andthe flow of air through the duct stops, too. In use, the furnace fanproduces a high pressure in the supply ducts and a low pressure in thereturn ducts. The high pressure forces warm air from the supply ducts toflow into the rooms, and low pressure draws room air back into thereturn ducts.

An inefficiency is created using conventional return distribution boxes,such as the prior art air distribution box shown in FIGS. 1 and 2. Here,due to the severe bending of the ducting that is required to mate to theupright connection flange of the air distribution box and the limitedspace available within the opposing trusses of the structure, thecross-sectional area of the return ducting is crimped and restricted,which reduces the efficiency of the air flow between the airdistribution box and the central furnace. This inefficiency can causeair leakage into the structure even if neither the supply nor the returnducts leak themselves. This is illustrated in a room that has a supplyregister and a partially constricted return register. This room will bepartially overpressured and air will leak out from the room, whichplaces an added load on the heating equipment.

Thus, there is a need for an air distribution duct that provides forefficient transport of air through the air ventilation system becausethe amount of heating and air conditioning needed will be much less thanin the prior art conventional installation. The air distribution box ofthe present invention permits the use of a smaller furnace and airconditioner, which require a smaller amount of air flow in the ductsystem.

SUMMARY

In one embodiment, the air distribution box for a ventilation air systemcomprises a housing defining an air passageway between an inlet and adownstream outlet in communication with the ventilation air system. Inone aspect, the inlet has a peripheral edge formed by the proximal endof the side walls of the housing. In a further aspect, the inlet ispositioned in an inlet plane. The outlet of the air distribution box isdefined in an outlet side wall that is positioned at an acute angle withrespect to the inlet plane such that at least a portion of the outletfaces a portion of the inlet.

Related methods of operation are also provided. Other systems, methods,features, and advantages of the air distribution box for a ventilationair system will be or become apparent to one with skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description, be within the scope ofthe air distribution box for a ventilation air system, and be protectedby the accompanying claims.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate certain aspects of the instantinvention and together with the description, serve to explain, withoutlimitation, the principles of the invention. Like reference charactersused therein indicate like parts throughout the several drawings.

FIG. 1A is a perspective view of a prior art air distribution box thatis mountable between truss members of a structure.

FIG. 1B is a side elevational view of the prior art air distribution boxof FIG. 1A, showing a partially constricted return duct mounted to theprior art distribution box.

FIG. 2 is a perspective view of a first embodiment of the airdistribution box of the present invention.

FIG. 3 is a perspective view of the air distribution box of FIG. 2mounted between a pair of truss members and connected to a conventionalflexible return duct.

FIG. 4 is a side elevational view of an alternative embodiment of theair distribution box of the present invention, showing an elongate airdischarge tube that is configured to connect to the proximal end of thereturn conduit.

FIG. 5 is a side elevational view of the air distribution box of FIG. 2.

FIG. 6 is an exploded view of an air distribution box of the presentinvention, showing a housing, a grill mountable to the housing, and afilter positionable therein the housing.

FIG. 7 is an assembled cross-sectional view of the air distribution boxof FIG. 6, taken across line 7-7 of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this invention is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,as such can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used herein, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, reference to a “peripheral support member” includes aspectshaving two or more such peripheral support members unless the contextclearly indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The present invention may be understood more readily by reference to thefollowing detailed description of preferred embodiments of the inventionand the examples included therein and to the Figures and their previousand following description.

In one embodiment, the air distribution box 10 of the present inventioncomprises a housing 20 for use in a conventional forced air ventilationsystem. For example and not meant to be limiting, such a conventionalair ventilation system can comprise a return conduit 2 for receiving airfrom a proximal end of the return conduit and subsequently deliveringthe return air to a central heating/air-conditioning system. In oneaspect, the housing 20 is configured to be positioned adjacent to atleast one support member 4, such as, for example a truss, of astructure. As one will appreciate, each support member extends apredetermined height dimension D_(s) between a top surface and anopposed bottom surface. For example, a conventional truss can have a 12″height dimension.

The housing 20 comprises an inlet 22 and a downstream outlet 24 incommunication with the return conduit 2 of the air ventilation system.In one aspect, the housing 20 comprises four substantially planar sidewalls 26 and defines an air passageway 28 extending between the inletand the outlet. In one aspect, the housing can be formed from sheetmetal, a polymer, or the like.

In one example, the inlet 22 of the housing has a peripheral edge 23that is formed by the proximal ends 27 of the four side walls. In afurther aspect, the peripheral edge 23 of the inlet is positioned in aninlet plane 25. In one example, the inlet 22 is substantially co-planarto the bottom surface of the at least one support member 4 when thehousing 20 is mounted to the structure. Thus, in this example, the inletplane 25 can be is substantially parallel to the bottom surface of therespective at least one support member. In a further aspect, the housing20 has a depth dimension D_(h) that is normal to the inlet plane 25 thatis less that the height dimension of the at least one support member.Thus, in the example of a 12″ truss, the housing 20 has an overallheight that is less than the height dimension of the truss.

In a further aspect, the outlet 24 of the housing is defined in anoutlet side wall 30 of the four side walls of the housing. The outletside wall 30 is positioned at an acute angle θ with respect to the inletplane 25 such that at least a portion of the outlet faces a portion ofthe inlet 22. Accordingly, in one aspect, the acute angle θ can have arange of from between about 5 to 85 degrees, which includes exemplaryangles of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, and 80degree.

In one example, the housing further comprises a top wall 32 that isconnected to the distal ends 29 of the four side walls. In this aspect,the top wall 32 is spaced a predetermined distance D_(h) from the inletof the housing. As one will appreciate, the top wall is spaced from theinlet a dimension that is less than the height dimension of thestructural member to which it is mounted for support.

Referring to FIGS. 3 and 5, in one example, the housing of the airdistribution box 10 of the present invention has a trapezoidalcross-sectional shape. In this example, the top wall 32 of the housing20 is substantially parallel to the inlet plane. In one example of thisaspect, the trapezoidal cross-sectional shape of the housing 20 forms anisosceles trapezoid shape.

In another aspect, the housing 20 further comprises a mounting flange 40that extends outwardly therefrom at least a portion of the peripheraledge 23 of the inlet 22 substantially co-planer to the inlet plane 25.In use, at least a portion of the mounting flange 40 can be used tomount the housing 20 to the at least one support member 4.Alternatively, at least one mount member 8 can be used to span anopposing pair of support members 4 and at least a portion of themounting flange 40 of the housing 20 can be mounted thereto the at leastone mount member. In one exemplary aspect, the mount member has a lip 9that is folded over to form a slot that is configured for receipt of themounting flange 40 of the housing. In this aspect, it is contemplatedthat, while the mount members are fixed to the respective supportmembers, the housing can me moved or slid longitudinally along theelongate lengths of the respective mount members into a desired positionrelative to the mount members.

In another aspect, the housing 20 further comprises a collar 44 thatextends outwardly therefrom at least a portion of a peripheral edge 45of the outlet 24 substantially normal to the outlet side wall 30. Inthis example, the collar 44 is configured to mount to conventional ducttubing, such as, for example, the proximal end of a flexible returnconduit 4.

In an alternative embodiment shown in FIG. 6, the outlet 24 of thehousing 20 comprises an elongate discharge tube 46. In this aspect, thedistal end 48 of the discharge tube 46 is configured to connect to theproximal end of the return conduit 4. In a further aspect, the dischargetube 46 can extend substantially parallel to the inlet plane 25 so thatthe distance between the housing's top wall and inlet remain the maximumheight dimension of the housing 20.

In a further aspect of the invention, the housing can further comprise ashoulder member 47 that extends outwardly therefrom the peripheral edge23 of the inlet away from the inlet plane 25 of the housing. In oneaspect, the shoulder member substantially surrounds the inlet 22 of thehousing. Alternatively, the shoulder member can extend therefrom atleast a portion of the peripheral edge of the inlet. In another aspect,the shoulder member 47 extends outwardly from the peripheral edge of theinlet substantially transverse to the inlet plane 25.

Turning to FIGS. 7 and 8, an alternative embodiment of the airdistribution box 10 of the present invention is illustrated. In oneaspect of this embodiment, the air distribution box further comprises agrill 50 that, in one exemplary aspect, is attachable to the mountingflange 40 of the housing 20 and configured to overlie the inlet 22 ofthe housing. The grill 50 can be attached to the mounting flange 40 byconventional fasteners 52, such as and not meant to be limiting, screws,bolts, clips, and the like. It is contemplated that the grill can bereleaseably mounted to the mounting flange or fixedly mounted to themounting flange.

In a further aspect, the air distribution box 10 of the presentinvention can comprise a filter 60 positionable between the mountingflange 40 of the housing and the grill 50. In this aspect, the grillforms a circumferentially extending and inwardly facing trough 54configured to accept a shoulder member 62 of the filter. A suitablegrill 50 is one manufactured by Barnett, model number 19FG-16X25W, itbeing understood that other grills are acceptable so long as they canhold and transmit the desired filter.

In another aspect, the filter 60 is configured to extend therein thehousing 20 a predetermined distance. For example, the filter can beconfigured such that the respective sides 64 of the filter 60 arepositioned proximate a portion of the four side walls 26 of the housing20. Alternatively, the filter 60 can be configured such that at least aportion of the respective sides 64 of the filter are in contact with aportion of the interior surface of the housing. In a further aspect, atleast a portion of the housing 20 proximate the inlet 22 can beconfigured to seat the filter and/or at least a portion of the grill.For example and not meant to be limiting, at least a portion of theinlet portion of the housing can be configured to receive at least aportion of a generally rectangular filter therein the interior volume ofthe housing. One will appreciate that conventional filters, such as, forexample and not meant to be limiting, ones manufactured by HoneywellInternational or by Purolator® Air Filtration, it being understood thatother conventional filters are acceptable so long as they are mountablewithin the inlet portion of the housing 20.

The preceding description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Other embodiments of the invention will be apparentto those skilled in the art from consideration of the specification andpractice of the invention disclosed herein. Thus, the precedingdescription is provided as illustrative of the principles of the presentinvention and not in limitation thereof. It is intended that thespecification and examples be considered as exemplary only, with a truescope and spirit of the invention being indicated by the followingclaims.

1. An air distribution box for a ventilation air system of the type thatincludes a return conduit for receiving air from a proximal end of thereturn conduit and for positioning adjacent at least one support memberof a building, each support member extending a predetermined heightdimension between a top surface and an opposed bottom surface,comprising: a housing having an inlet and a downstream outlet incommunication with the return conduit, the housing comprising foursubstantially planar side walls and defining an air passageway betweenthe inlet and the outlet, wherein the inlet has a peripheral edge formedby the proximal ends of the four side walls that is positioned in aninlet plane, and wherein the outlet is defined in an outlet side wall ofthe four side walls of the housing, the outlet side wall beingpositioned at an acute angle with respect to the inlet plane such thatat least a portion of the outlet faces a portion of the inlet.
 2. Theair distribution box of claim 1, wherein the inlet plane issubstantially parallel to the bottom surface of the respective at leastone support member, and wherein the housing has a depth dimension normalto the inlet plane that is less that the height dimension of the atleast one support member.
 3. The air distribution box of claim 1,wherein the housing is formed from sheet metal.
 4. The air distributionbox of claim 1, wherein the housing comprises a top wall that isconnected to the distal ends of the four side walls, the top wall beingspaced a predetermined distance from the inlet of the housing.
 5. Theair distribution box of claim 4, wherein the housing has a trapezoidalcross-sectional shape, and wherein the top wall is substantiallyparallel to the inlet plane.
 6. The air distribution box of claim 5,wherein the trapezoidal cross-sectional shape forms an isoscelestrapezoid shape.
 7. The air distribution box of claim 1, wherein thehousing further comprises a mounting flange that extends outwardlytherefrom at least a portion of the peripheral edge of the inletsubstantially co-planer to the inlet plane.
 8. The air distribution boxof claim 1, wherein the housing further comprises a collar that extendsoutwardly therefrom at least a portion of a peripheral edge of theoutlet substantially normal to the outlet side wall.
 9. The airdistribution box of claim 1, wherein the acute angle is less than about75°.
 10. The air distribution box of claim 1, wherein the acute angle isless than about 60°.
 11. The air distribution box of claim 1, whereinthe acute angle is less than about 45°.
 12. The air distribution box ofclaim 1, wherein outlet of the housing further comprises an elongate airdischarge tube extending substantially parallel to the inlet plane, thedistal end of the air discharge tube configured to connect to theproximal end of the return conduit.
 13. The air distribution box ofclaim 7, further comprising a grill releasably attachable to themounting flange of the housing and configured to overlie the inlet ofthe housing.
 14. The air distribution box of claim 13, furthercomprising a filter positionable between the mounting flange of thehousing and the grill.
 15. The air distribution box of claim 14, whereinthe grill forms a circumferentially extending and inwardly facing troughconfigured to accept a shoulder member of the filter.
 16. The airdistribution box of claim 15, wherein the filter is configured to extendtherein the housing a predetermined distance and is configured such thatthe respective sides of the filter are positioned proximate a portion ofthe four side walls of the housing.
 17. An air distribution box for aventilation air system of the type that includes a return conduit forreceiving air from a proximal end of the return conduit and forpositioning adjacent at least one support member of a building, eachsupport member extending a predetermined height dimension between a topsurface and an opposed bottom surface, comprising: a housing having aninlet and a downstream outlet in communication with the return conduit,the housing defining an air passageway between the inlet and the outlet,the inlet being positioned in an inlet plane and the outlet beingdefined in an outlet side wall of the housing, the outlet side wallbeing positioned at an acute angle with respect to the inlet plane suchthat at least a portion of the outlet faces a portion of the inlet,wherein the housing further comprises a mounting flange that extendsoutwardly therefrom the inlet substantially co-planer to the inletplane; a grill configured to overlie the inlet of the housing; and afilter positionable therein a portion of the air passageway proximatethe inlet of the housing, wherein the filter underlies the grill. 18.The air distribution box of claim 17, wherein the grill forms acircumferentially extending and inwardly facing trough configured toaccept a shoulder member of the filter.
 19. The air distribution box ofclaim 17, wherein the filter is configured to extend therein the airpassageway of the housing a predetermined distance and is configuredsuch that at least a portion of a peripheral exterior surface of thefilter is positioned proximate a portion of an interior surface of thehousing.
 20. The air distribution box of claim 17, wherein the inletplane is substantially parallel to the bottom surface of the respectiveat least one support member, and wherein the housing has a depthdimension normal to the inlet plane that is less that the heightdimension of the at least one support member.